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So my kid has lost a bunch of these shapes and I'm going to make a replacement set.
Does anyone have any ideas for how to get a consistent roundover on the corners? I have a router table but no CNC.
The square and rectangle I could do with a roundover bit and the blocks on their sides. But I don't see any obvious solutions for the pentagon and triangle.
I'm totally fine just hand sanding these, but this kind of problem solving makes woodworking fun!
Router and template! Use a band saw or jig saw or even a coping saw to cut out the shapes in MDF or something. Use a 1/2" drill bit as a template and draw on your rounded corners. And then sand or file or rasp them to shape. THEN use a flush trim router bit and go to town!
An idea that came to mind.. I do have a 3D printer so I could make 120° and 72° round radius guides like these.
Instead of just corner guides, 3d print entire templates. Then double-stick tape them to your wood and use a pattern bit in your router. Pattern bits are different from a flush cut bit, the bearing is on the opposite end.